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Abstract:

Apparatus, systems and methods are disclosed to manufacture a plurality
of edible pieces in a continuous process where each piece is generally
different in thickness, shape, size and/or texture from another piece, so
as to create, in the aggregate product distribution, pieces of randomly
varying thickness, size, shape and/or texture. More specifically, the
present invention, in its various embodiments, provides a process for
manufacturing pet jerky treats comprising: grinding proteinaceous
material, mixing said proteinaceous material with preservatives and
flavor enhancers to form a blend of foodstuff, extruding said foodstuff
through at least one die opening that is at least partially irregular to
form at least one strip of extrudate that is at least partly irregular in
shape, transporting said strip in a first longitudinal direction to a
first cutting operation, cutting said strip at a first cutting angle to
form a first set of pieces, transporting said first set of pieces in a
second longitudinal direction to a second cutting operation, cutting said
first set of pieces in said second cutting operation at a second angle to
form a second set of pieces, such that the said second set of pieces
cumulatively produced during a process run generally appear to be of
random sizes and shapes.

Claims:

1. A process for manufacturing pet jerky treats comprising: grinding
proteinaceous material, mixing said proteinaceous material with
preservatives and flavor enhancers to form a blend of foodstuff,
extruding said foodstuff through at least one die opening that is at
least partially irregular to form at least one strip of extrudate that is
at least partly irregular in shape, transporting said strip in a first
longitudinal direction to a first cutting operation, cutting said strip
at a first cutting angle to form a first set of pieces, transporting said
first set of pieces in a second longitudinal direction to a second
cutting operation cutting said first set of pieces in said second cutting
operation at a second angle to form a second set of pieces, such that the
said second set of pieces cumulatively produced during a process run
generally appear to be of random sizes and shapes.

2. The process of claim 1 wherein said strip is transported by a
conveyor.

3. The process of claim 1 wherein said first set of pieces are
transported by a conveyor.

4. The process of claim 1 wherein the first cutting angle is
substantially perpendicular to the first longitudinal direction.

5. The process of claim 1 wherein the second cutting angle is
substantially perpendicular to the second longitudinal direction.

6. The process of claim 1 wherein the angle between the first
longitudinal direction and the second longitudinal direction is between
30 and 60 degrees.

7. The process of claim 1 wherein at least one of the said first or
second cutting operations uses serrated blades.

8. The process of claim 1 wherein at least one of the said first or
second cutting operations uses rotary blades.

9. The process of claim 1 wherein said second cutting operation has a
combination of rotary and serrated blades that pull and tear said first
set of pieces.

10. A manufactured animal treat product, comprising: first and second
integral textured extruded surfaces, a median distance between said
surfaces of said treat product defining said product's thickness; opposed
first and second rough textured cut edges on said surfaces; and opposed
third and fourth nonlinear rough textured cut edges on said surfaces,
said third and fourth edges adjacent to said first and second edges, said
first, second, third and fourth edges predominantly forming a
circumference of said animal treat product surfaces, wherein the median
distance between said first edge and said second edge is substantially
greater than said product thickness.

11. The manufactured animal treat product of claim 10 wherein said first
and edges are substantially linear.

12. The manufactured animal treat product of claim 10 that contains from
about 40% to about 95% by weight of said proteinaceous material, and
where said proteinaceous material is selected from the group comprising
one or more of the following: beef, chicken, pork, turkey, venison,
offal, soy or vegetable protein.

13. The manufactured animal treat product of claim 10 having less than
20% by weight of starch.

14. The manufactured animal treat product of claim 10 having from about
15% to about 30% by weight of stabilized moisture content under normal
storage conditions.

15. The manufactured animal treat product of claim 10 having a stabilized
water activity between 0.60 and 0.78 under normal storage conditions.

16. The manufactured animal treat product of claim 10 wherein the ratio
of the median distance between said first and second edges, and the
product thickness, can vary from about 1:1 to about 14:1.

17. The manufactured animal treat product of claim 10 wherein said treat
is a protein based jerky product having a substantially non-uniform
appearance redolent of traditional jerky products made for human
consumption.

18. A process for manufacturing pet jerky treats comprising: extruding a
ground proteinaceous mix through at least one die opening that is at
least partially irregular to form at least one strip of extrudate that is
at least partly irregular in shape, transporting said strip placed in an
initial orientation on the surface of first conveyor moving in a first
longitudinal direction to a cutting operation, cutting said strip at a
first cutting angle that is not parallel to said longitudinal direction
to form a first set of pieces, transporting said first pieces back to
said first conveyor and placing them on conveyor surface in an
orientation that is generally different from said initial orientation
cutting said first set of pieces again at said cutting operation to form
a second set of pieces that are generally smaller than said first set of
pieces, such that the said second set of pieces cumulatively produced
during a process run generally appear to be of random sizes and shapes.

19. An apparatus for reducing the size of foodstuff comprising: a
conveyor for conveying a plurality of foodstuff along a longitudinal
path, a first cutting device overlying said longitudinal path that has a
reciprocating mechanism for cutting said foodstuff at a first angle that
is not parallel to the said longitudinal path so as to form smaller food
pieces, a second cutting device overlying said longitudinal path that has
a reciprocating mechanism for cutting said pieces at a second angle that
is different from said first angle, where first and second angles can
also be varied dynamically during the process so that the sliced food
pieces cumulatively produced during a process run generally appear to be
of randomly varying sizes and shapes.

20. An apparatus for reducing the size of foodstuff comprising: a first
conveyor that is operable along a longitudinal path, said conveyor also
operable to have a plurality of foodstuff placed in an initial
orientation on its surface, a first cutting device overlying said
longitudinal path that has a reciprocating mechanism for cutting said
foodstuff at a first angle that is not parallel to the said longitudinal
path so as to form smaller food pieces, a mechanism for recycling said
smaller food pieces back to said first conveyor and repositioning them on
said surface in an orientation that is generally different from said
initial orientation so that the food pieces cumulatively produced during
a process run with at least two cutting steps generally appear to be of
random sizes and shapes.

Description:

FIELD OF THE INVENTION

[0001] The present invention generally relates to apparatus, systems and
methods for manufacturing food, more specifically jerky-styled pet food
products, of variable thickness and texture, and in irregular, randomized
shapes and sizes.

BACKGROUND OF THE INVENTION

[0002] A large and growing number of households have pets. Studies have
shown that pet owners often treat their pets as they treat close friends
and relatives. Owners include pets in holiday celebrations, and often
refer to themselves as parents of their pets. Such affinity is tangibly
demonstrated in the rapid growth of a multibillion dollar pet industry
with an increasing demand for pet products that mimic human products.

[0003] Health conscious consumers are also demanding higher quality pet
food that is not only closer in ingredient quality to human food, but
also looks less processed and more natural. However, conventional pet
food producers seldom focus on the visual impact of pet food that
heightens aesthetic appeal to a purchaser, even if they integrate
advanced ingredients more commonly found in food produced for human
consumption. Since a traditional manufacturing goal is reproducibility
and uniformity, industrial cutting machines used in these conventional
pet food processes are primarily designed to deliver products with
consistency in shape, texture and size. Therefore, pet food packages
typically contain edible pieces, or kibbles, where each kibble is
generally of uniform shape and size, often readily appearing glazed or
processed. For example, pet jerky treats are made by extrusion through
generally uniform die openings, producing strips or rods that are
typically uniform in shape, and which are then typically cut in uniform
pieces that are rectangular (flat) or cylindrical (rod) in appearance.
Pet food resembling red meat marbled with fat has been made by extruding
or pressure casting a blend of red meat and white fat, but the end
product is again a plurality of food pieces of generally uniform shape
and size.

[0004] Manufacturing techniques used to produce human food are often not
cost effective for pet foods. For example, jerky-style products for human
consumption are made from sliced premium muscle meat, and contain almost
no grains, starch or carbohydrates. Because of the high concentration of
muscle meat and fat, increased time is required for processing of human
grade jerky, especially drying. The increased use of meat, lack of
carbohydrates, and the slower drying process results in a final product
that shrinks and forms into long strips of randomly wrinkled meat, in the
distinct rugged appearance of natural jerky with which consumers are
familiar, and often associate with higher quality.

[0005] While human grade jerky may certainly be used as pet food, it would
be cost prohibitive for most pet owners. This is because human grade
jerky is primarily marinated meat, often costly premium meat. When the
product is almost 100% meat, it also becomes difficult to process
efficiently in high volumes, thereby increasing processing time and
costs. To reduce ingredient costs, pet jerky treats use lower amounts of
meat (typically 20-40%), and usually do not use any premium muscle meat.
To compensate for lower amounts of meat in pet jerky, 20-40% of flour or
starches must be added, along with other ingredients such as vegetables,
preservatives, and flavor enhancers. Besides lowering ingredient costs,
the flour and starch significantly improve processing ability for high
volume manufacturing, further reducing production times and costs.

[0006] Human grade jerky is usually designed for relatively short shelf
lives. Pet food, on the other hand, is engineered to be stored (if
necessary) for eighteen months after manufacturing before it is consumed,
and therefore requires a substantially longer shelf life. Human grade
jerky packets, once opened, become stale in less than a week. Pet jerky,
however, is expected to last for up to three months after the package is
opened. The delay in the storage and consumption of pet foods requires
more careful ingredient selection, preservation of freshness with
antioxidants, processing that avoids insects and rancidity, careful
packaging and storage. This kind of food processing, with a higher mix of
inexpensive ingredients, particularly carbohydrates, lends itself well to
traditional extrusion techniques.

[0007] Since high moisture meat products tend to spoil quickly, such
products are usually sold in cans in the pet food market, and are more
typical as cat food. Pet food or kibble with low moisture content
(typically less than 10%), are dry and hard, and less palatable to pets.
Semi-moist pet food, typically having moisture content between 15 and
30%, is very popular with animals since it has a texture and palatability
that is closest to meat. However, as discussed, semi-moist pet food is
difficult to store in a stable condition, without canning or
refrigeration, for long periods.

[0008] Thus, neither conventional pet food manufacturing processes nor
traditional production techniques of jerky-style products for human
consumption can meet the requirements of cost-effectively manufacturing
jerky products for pets of variable thicknesses, texture, and non-uniform
shapes and sizes that remain semi-moist, and shelf-stable without
refrigeration for long periods under normal storage conditions.
Furthermore, there is no conventional food processing method for either
pet or human food that can produce a continuous line of jerky pieces that
mimic the natural, irregular, wrinkled and rugged look and feel of human
grade jerky produced traditionally.

SUMMARY OF THE INVENTION

[0009] Illustrative embodiments of the present invention include
apparatus, systems and methods for manufacturing a plurality of edible
pieces in a continuous process where each piece is generally different in
thickness, shape, size and/or texture from another piece, so as to
create, in the aggregate, product pieces of randomly varying thickness,
size, shape and/or texture. More specifically, the various embodiments
provide a method to manufacture a pet jerky treat that is not only of
good nutritional quality, but also mimics the natural, wrinkled, rugged
and random appearance and texture of jerky products that are designed for
human consumption. While embodiments are described primarily with respect
to pet food products and pet jerky products in particular, it should be
appreciated that the disclosed apparatus, systems and methods may be
applied to the cost-effective production of a broad range of food
products, whether intended for pet or human consumption.

[0010] More specifically, one illustrative embodiment of the present
invention provides a process for manufacturing pet jerky treats
comprising: grinding proteinaceous material, mixing said proteinaceous
material with preservatives and flavor enhancers to form a blend of
foodstuff, extruding said foodstuff through at least one die opening that
is at least partially irregular to form at least one strip of extrudate
that is at least partly irregular in shape, transporting said strip in a
first longitudinal direction to a first cutting operation, cutting said
strip at a first cutting angle to form a first set of pieces,
transporting said first set of pieces in a second longitudinal direction
to a second cutting operation, cutting said first set of pieces in said
second cutting operation at a second angle to form a second set of
pieces, such that the said second set of pieces cumulatively produced
during a process run generally appear to be of random sizes and shapes.

[0011] It will be appreciated by those skilled in the art that the
foregoing brief description and the following detailed description are
exemplary and explanatory only, and are not intended to be restrictive
thereof or limiting the invention. Thus, the accompanying drawings,
referred to herein and constituting a part hereof, illustrate only
preferred embodiments of the invention, and, together with the detailed
description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is an overview of a process for making irregularly shaped
jerky, according to an illustrative embodiment of the invention.

[0013] FIGS. 2A and 2B show details of the extrusion manifold (160) of the
process of FIG. 1, according to an illustrative embodiment of the
invention.

[0014]FIG. 3 is a more detailed overview of the random sizing step 180 of
the process in FIG. 1, according to an illustrative embodiment of the
invention.

[0015] FIGS. 4A, 4B and 4C show details of the cutting/shredding process
of FIG. 3, according to an illustrative embodiment of the invention.

[0016] FIGS. 5A and 5B shows possible shaping patterns of the jerky
product after the cutting/shredding process of FIG. 4 and just before the
packaging step (185) of FIG. 1, according to an illustrative embodiment
of the invention.

[0017] FIGS. 6A, 6B and 6C shows different views of the notched cross cut
blade used in the cutting/shredding process (350) of FIG. 3, according to
an illustrative embodiment of the invention.

[0018] FIGS. 7A, 7B and 7C show different views of the cutting/shredding
process (350) using notched crosscut blades and star shaped blades,
according to an illustrative embodiment of the invention.

[0019] FIGS. 8A, 8B and 8C show further details and different views of
dual cut crosscut blades mounted to a crosscut spindle (740C of FIG. 7),
according to an illustrative embodiment of the invention.

[0020]FIG. 9 shows possible shaping patterns for final jerky product
pieces after a combination of notched and dual reduction cutting
processes, according to an illustrative embodiment of the invention.

[0021] FIG. 10 shows a final jerky product pieces that have jagged or
pulled edges, according to an illustrative embodiment of the invention.

[0022] FIG. 11A shows a photograph of 20 beef jerky treats in generally
random sizes, shapes and textures, which were made according to an
embodiment of the invention.

[0024] Illustrative and alternative embodiments and operational details of
apparatus, systems and methods to manufacture a plurality of irregular,
random edible pieces of varying texture in a continuous process will be
discussed in detail below with reference to the figures provided. One
preferred product, however, is an edible food product for animal
consumption, more particularly a pet treat or jerky containing meat or
meat analogs.

[0025] In one illustrative embodiment of the invention shown in FIG. 1,
frozen blocks of premium muscle meat or any appropriate proteinaceous
material are processed through a first grinder (100). This grinder has
relatively large grinder plate openings (larger than 1/2×11/2
inches in nominal diameter but no larger than 4×7 inches each),
resulting in large chunks of meat with more longitudinal grains. A
variety of geometrical and non-geometrical shapes can be used for the
grinder plate openings (e.g., rectangular, trapezoid, teardrop, etc.) to
add to the textural properties of the final product. Frozen blocks of pet
grade meat are processed through a second grinder (110) with smaller
grinder plate openings (larger than 1/16'' diameter but smaller than 1''
diameter). This dual grinding step and/or the use of premium muscle meat
can also contribute to the appearance and texture of the final jerky
product.

[0026] The ground meat is batched and mixed in a ribbon flight mixer
(130), typically a ribbon flight mixer, sigma blade, solid screw or any
similar mixing equipment common in food processing. Dry ingredients (120)
are added to the meat batch in the mixer, and the details of the
ingredients and proportions are described in TABLE 1, further below. The
mixed batch is processed with a third grinder (140) that assists in the
consistent mixing of both longitudinal grains and smaller chunks of meat
in such a way that the resultant meat emulsion can be extruded easily.
This additional grinding step can also contribute to the appearance and
texture of the final jerky product. Note also that while the grinding and
mixing steps described herein are a preferred embodiment, similar results
can also be attained by separately sourcing pre-ground (and pre-mixed)
proteins and other ingredients, and then using this externally sourced
ground mix as the starting raw material to carry out the rest of the
process steps described in FIG. 1 and below.

[0027] After the final grind (140), the meat emulsion is fed (150) to a
positive displacement pump (155), from which it is conveyed to an
extrusion manifold (160). Here, the product is extruded through an
extrusion manifold having generally irregular die openings. Irregular as
referred to herein, indicates that the die opening can be shaped in any
combination of linear, non-linear, curved, geometric, symmetrical or
non-symmetrical, uniform or non-uniform pattern that can vary across the
nominal dimensions of the die opening. Further, part of the contour of
the die opening can be regular and uniform whereas the rest of the
contour is irregular, as for instance a rectangular slit where one of the
sides of the rectangle is replaced by a wavy or non-linear pattern. For
clarity, an illustrative embodiment of such an extrusion manifold is
detailed in FIG. 2A (item 200A) and the corresponding isometric view in
FIG. 2B (item 200B). The die openings and/or inner surfaces of the
extrusion manifold (160, 200A, 200B) can have a variety of patterns of
differing dimensions and shapes as illustrated in 210A, 220A, 230A or
240A. When the meat emulsion is extruded through this manifold, it
produces extruded strips of varying thickness and shapes with a unique
texture, as shown in FIG. 2B. For instance, the jerky strips can be
extruded through a die containing several slots having various waved or
ridged patterns, with a resulting interim product distribution having a
range of surface contour patterns, from a smooth transitioned wave
pattern (240B) to a more granular rippled surface (210B). Further, the
bottom of one or more of the extrusion die openings (210A, 220A, 230A or
240A) can also be of varying or irregular shape. It must also be
emphasized that, because of further downstream processing (described
below), extrusion die openings of substantially regular and uniform
linear patterns can also be used in this step of the process to achieve a
similar end result, so long as at least one of the extruder die openings
used in the process is at least slightly irregular, e.g., has a curved or
non-linear contour.

[0028] In FIG. 2B, four strips (210B-240B), typically about 21/2'' wide,
are extruded continuously, cut with any typical post-extrusion cutting
process (water jets, pinching cleats, knife blades, etc.) onto
12''×48'' long plastic trays (250B) transferred with a belt
conveyor. Cleats are preferred. This step acts as an initial product
sizing operation (165). Note, however, that the product could also be
extruded directly onto a continuous belt conveyor. The number and size of
the extrusion patterns and openings, whether they are of similar or
different sizes, may vary, and is related to the width of the trays or
belt used in the process. If trays are used, the extrudate (210B-240B) is
cut to the length of the trays (250B) with the cleats, and the trays are
then conveyed over a roller to the next step, drying (170) for about 4-5
hours. Typically, a continuous oven dryer is used, though any similar
equipment used in food processing will suffice.

[0029] As shown in FIG. 1, the extrudate is then dried in an oven (170)
between 130-250° F., for 4-8 hours, depending on the dimensions of
the strips, initial product moisture, etc. The higher the temperature,
the shorter the drying time required. The temperature and drying profiles
are important to prevent the generation of skin or excessive dehydration
or shriveling of the product. After drying, the jerky is cooled (175) for
1-4 hours, typically at ambient temperature, before continuing to the
next step of the process: random sizing (180). The drying and cooling
process conditions and parameters also contribute to the final texture
and roughness of the finished product.

[0030] Random sizing as referred to herein is the process of making
smaller pieces from the extrudate strips (e.g., 210B) in such a way that
each piece made generally appears to be different in terms of thickness,
shape, size and/or texture from subsequently or previously produced
pieces. This creates, in the aggregate, pieces of varying thickness,
size, shape and/or texture that simulate an overall collection of
haphazard, unsystematic or non-uniform collection of pieces that appear
to have no governing design or method. The goal is to simulate the
natural, wrinkled, rugged and non-uniform appearance of human grade jerky
products but, as one skilled in the art will appreciate, this goal can
rarely be completely realized, and a reasonable amount of variation is
sufficient in actual practice. To emphasize, random sizing is not
intended to mean that a particular piece is always designed to be
different in dimension, shape or texture from another piece, or that
there will not be two or more identically (or even similarly) shaped or
sized pieces that could be found in a collection of pieces that are
produced in any process run. FIGS. 11A and 11B are a further illustration
of type of irregular and arbitrary product sizes and shapes that can be
achieved through an illustrative embodiment of the present invention.

[0031]FIG. 3 shows one illustrative embodiment of the random sizing
process where jerky treats of variable thicknesses, textures, shapes and
sizes, with jagged, rough, ripped, or shredded product edges are made. To
assist in the description of this process, it is helpful to first discuss
conventional approaches to cutting systems.

[0032] In conventional continuous cutting systems, cross-cutting and
dicing are processes in which the cutting elements are horizontal or
perpendicular to the direction of the motion of the product, which
results in products that are typically uniform in shape. When
cross-cutting processes are used, the product is typically cut by a blade
or series of blades whose cutting edge is parallel to their rotational
axis. The cutting circle of a crosscut blade is the circular path that
the cutting edge of the blade travels while rotating about an axis. The
size of the cut depends on the portion of product that crosses into the
cutting circle when it comes into contact with the blade. Since
cross-cuts are typically carried out with straight edge blades, it
results in clean, uniform product edges.

[0033] Unlike the conventional method discussed in the preceding
paragraph, FIG. 3 overviews a three-step process, consisting of a first
cutting operation, followed by a change of product flow orientation,
followed by a second cutting operation.

[0034] In the first step, dried and cooled jerky strips are fed through
the first conveyor (300) to a first cutter/shredder (310) to obtain 6-8''
long strips (320). Typically, the cutter/shredder used in this first
cutting operation has a single mounted blade with a single cut surface.
However, more complex cutters/shredders, with serrated or notched
crosscut blades and holding spurs, can also be used in this step to
increase the roughness and texture. The crosscut blade is notched to
allow the blade to act as a set of teeth that dig into the product
without completely separating the cutting section from the product main
body. The main body is held in place by a device which may include
holding spurs, roller(s), an overhead conveyor, etc. while the rotation
of the notched crosscut blade pulls the cut section away from the main
body. In the absence of the holding device, an additional process may be
implemented to separate the product from the main body including but not
limited to manual separation. The result is a non-linear/ripped product
edge as shown in FIG. 10 or FIG. 11A.

[0035] In the second step, the 6-8'' strips (320) are then transferred to
an aligning conveyor (330). This conveyor switches the orientation of the
strips and aligns the strips for being cut in a different orientation
during the third step. The aligning conveyor also spaces the strips
before placing it on the in-feed conveyor (340), which then feeds the
strips to the next cutter/shredder (350) in an oblique orientation. The
longitudinal axis of the strips can be oriented anywhere between 1 and
89° with respect to the direction of travel on the in-feed
conveyor (340) for the next cutter/shredder (350), and is more typically
between 30 and 60°.

[0036] The third step (340, 350, 360), involves another cutting/shredding
operation (350), that uses a set of serrated or notched cutting blades or
a single blade that makes multiple cuts along the same cutting circle.
The random sizing process with these unique cross cut and shredding
systems results in a variety of irregularly shaped pieces--similar to
triangles, quadrilaterals, and other regular or irregular
polygons--continuously being made in a production line so that each
product that comes out is generally of a different size and shape than
the previous one, which eventually results in a plurality of product
pieces that are of substantially random shapes, sizes and texture.

[0037] One illustrative embodiment of the second cutter/shredder operation
(340-350) is illustrated in greater detail in FIG. 4A-C, and in FIG.
5A-B. This operation further changes the overall shape characteristics of
the jerky. The cutter/shredder (350) has either a blade or blade assembly
that will cut the interim product strips at two different times along the
same cutting circle, and it cuts using both rotary and crosscut blades.
The blade or blade assembly is the arrangement of notched straight blades
that will eventually result in the complete separation of the product
cutting section from the main body through shearing. A stepped cutting
also results from the product being fed into the cutting circle and cut
at different times. The angle between the cutting edges with respect to
the crosscut rotational axis determines the time that will elapse between
the initial and final cuts. The result is a generally a non-linear
product edge.

[0038] The rotary blades (410C), as shown mounted on the rotary blade
shaft (420C), provide a unique cut (430C, 520A) along the direction of
travel (500A). Meanwhile the crosscut blades (440C), as shown mounted on
the crosscut spindle (450C), rotate about the crosscut shaft (460C) and
provide a unique cut (470C, 530A) that is roughly perpendicular to the
direction of travel. Due to the oblique orientation of the jerky strips
(510A) relative to their direction of travel as they pass through the
cutter (500A), the resulting product pieces emerge in forms that are
similar to triangles, parallelograms, and other geometric and/or
irregular shapes of varying sizes (FIG. 5B), such that when a number of
edible pieces are sequentially produced and collected, the product
distribution in terms of shape, thickness, size and texture, appear
substantially random and irregular (see FIG. 10, 11A and 11B).

[0039] In the prior embodiment, the crosscut blades (440C) produce only a
straight cut. The straight edge provides a clean and even cut along the
product edge. In one embodiment of the subject invention, to give the
beef jerky edges an even more natural and torn appearance and texture,
the crosscut blades are notched (FIG. 6A) to obtain an uneven cut (730C).
In the absence of a continuous cutting surface, the remaining edges of
the crosscut blade (610A) penetrate the product like teeth. The motion of
the notched crosscut blade (FIGS. 6C and 700A) pulls/tears the lead
section of the product (710A), away from the product remainder (720A)
which is held in place by the sharp edges of star shaped blades (730A),
and this is also illustrated in FIG. 8A. While this is not necessary, to
simplify the assembly, the star shaped blades (700C) may be mounted on
the same shaft (710C) as the rotary blades (720C). In the event that the
notched crosscut blade does not effectively cut the product, crosscut
blades with two cutting surfaces (as shown in FIG. 8B mounted on the
crosscut spindle) may be used to ensure a thorough cut. The additional
cutting surface (800A, 800B) must generally follow the same cutting
circle (810B) as the primary cutting surface (810A, 820B), to provide a
staggered clean cut along the product edge. The result, of either the
notched crosscut blades (FIG. 6B) or the dual cutting surface blades
(FIG. 8B), is a jerky product with uneven, torn edges that appear to be
pulled apart by hand (FIG. 9 and FIG. 10). After the random sizing
operation described above, the product is then packaged in any of the
typical methods and processes used in the pet industry (185).

[0040] While the foregoing description explains the manufacturing process
used to make the product, it is also important to note that the type and
relative proportions of ingredients used in making the product can also
play a role in making variable thickness, irregularly shaped pieces, as
will be evident to one skilled in the art. In particular, the increased
proportion of meat used in this process helps develop a rough texture
that appears more like human grade beef jerky that is made from sliced
muscle meat.

[0041] Two recipes (A and B) are shown below to demonstrate some typical
proportions of proteins and other ingredients used in the beginning of
the process (FIG. 1 at mixer 130) to make a jerky treat for animal
consumption (numbers below are in weight percent):

[0042] While the recipes above are specific, TABLE 1 below illustrates the
broader ranges of composition of the key components that can be used in
conjunction with the process described herein to make proteinaceous jerky
treats for animal consumption. Some of these combinations would also be
useful for making long-lasting products for human consumption, as will be
appreciated by one skilled in the art. Note that many of these starting
ingredients (e.g., beef or chicken or vegetables) inherently contain
water.

[0043] Accelerated testing studies have also indicated that recipes A and
B produce pet products that are shelf stable for at least 18 months,
maintaining a stabilized intermediate moisture content (15-30% by weight,
usually 18-26%), and stabilized water activity (Aw ranging from 0.60 to
0.78, usually 0.65-0.75%) without refrigeration under normal conditions
of storage in homes or stores that are reasonable and expected for the
packaged pet foods industry. The ingredient mix, within the composition
ranges in TABLE 1 provided above, can also be adjusted as needed by one
skilled in the art to ensure that similar stabilized moisture content and
water activity is achieved to create final packaged products that are
semi-most and shelf-stable for at least 18 months.

[0044] It will be apparent to one skilled in the art that the final shape
and texture of the end products, and their size and thickness
distributions, can be pre-designed and/or manipulated on-the-fly during
the manufacturing process by pre-selecting and/or dynamically adjusting
various process variables. These variables include, but are not limited
to, the following: [0045] 1. Product orientation with respect to the
cutting elements in either of the two cutting operations. FIG. 3.
indicates a roughly perpendicular orientation between the first conveyor
alignment (300 to 320) and the first cutter/dicer (310) (hereafter "Angle
1"), and between the final conveyor alignment (340 to 360) and the second
cutter/dicer (350) (hereafter "Angle 2"). In alternative embodiments,
Angle 1 and/or Angle 2 can be made oblique, in practice typically between
30 and 150°. Further, Angle 1 can be the same or completely
different from Angle 2. [0046] 2. Conveyor flow orientation between first
and second cutting operations. In FIG. 3, the angle between flow in the
first cutting operation and the intermediate conveyor (330) (hereafter
"Angle 3"), is roughly 90°; the angle between the intermediate
conveyor and the second cutting operation (340, 350, 360) (hereafter
"Angle 4"), is roughly 45°. In alternative embodiments, Angle 3
and Angle 4 can be varied between 20 and 70°, and is preferably
between 35 and 55°. [0047] 3. Pattern, size and shape of extrusion
slots. In FIG. 2A, the extrusion slots are generally of the same length,
but of different patterns. This can be changed in a wide variety of ways,
with the length of each slot being different from each other to more
variation in the width of the slots. The design is of course dependent on
the end-user and market preferences; for instance, the small dog segment
may require smaller, more uniform slits, whereas larger variations are
possible for large dogs. [0048] 4. Width of the conveyor belt and size of
the cutter/shredder. If a wider belt or a larger cutter/shredder were
utilized, then the jerky strips could be a longer length, but these
dimensions can be adjusted as needed based on the size of the pet the
product is designed for, and other consumer and market preferences. Also
there is a wide variety of the types of blades that can be used in the
cutter/shredder. [0049] 5. Speed of the conveyor belt and/or cutting
frequency/speed of the blade(s) in the cutting operation. Changing the
speed of the conveyor belt allows dynamic control and variation in the
size and texture of the product. For example, slower (faster) speeds in
conveyor (300-320) will result in smaller (larger) pieces being produced,
for the same cutting frequency of the blades. The speeds can also be
varied differently in different conveyors and/or blades. [0050] 6.
Variations in composition within the ranges prescribed in Table 1. For
instance, increasing the meat concentrations and lowering or eliminating
carbohydrates will increase the leathery, wrinkled texture of the
product. Note that increasing the ratio of premium muscle meat to lower
grade meat (including offal), will also increase the natural wholesome
look, but this must be balanced with commercial considerations such as
cost and consumer preferences. To some extent, the composition can also
be adjusted dynamically during processing by adding multiple feed points,
each independently controllable, instead of the fixed ingredients
addition shown as (120) in FIG. 1. [0051] 7. Further processing with
additional alignment conveyors and cutting operations angles after the
end second cutting operation (350), to get finer cuts and an increase in
randomness and irregularity of the pieces. One skilled in the art can
also envision the possibility of using just one cutter/shredder operation
twice. In other words, the output of the cutting operation can be sent
back through a recycling conveyor to the beginning of the cutting
operation, at a different angle, so that the product is processed a
second time through the same cutter. In principle, this can be extended
to as many cutting and re-feeding operations as necessary, and limited
only be the requirements of the end product and its cost. [0052] 8. Use
of one or more (a) "cookie cutter" type stampers or irregular patterns
and shapes, or (b) cutters/slicing blades, that stamp/slice down
sequentially after the extrusion step (160) on to the conveyor belt
carrying the extrudate strips, at angle that is not perpendicular to the
longitudinal movement of the conveyor, such that the strips get cut out
in irregular patter ns after one (or more cuts) from these
stampers/cutters. [0053] 9. Adjusting the force and direction of the cuts
in one or more of the cutter/shredder operations. The angular force of
the cutting blades can be tuned to adjust the degree to which the product
strips are roughly torn by the blade edges rather than more precisely cut
in accordance with the blade contours. To achieve the desired level of
tearing/shredding, the angular force of the blades must be tuned relative
to the texture and overall consistency of the dried product strips.
[0054] 10. Changing the feed orientation for the second cutting operation
without the use of an alignment conveyor. For instance, referring to FIG.
3, any commercially available pick and place equipment may be used
instead of alignment conveyor (330) to pick up, change the orientation of
the strip(s), and place them back on the same conveyor (300-320) which
will then directly feed into the second cutting operation (340-360).
Another option is to have the output (320) feed into a constantly
revolving/tumbling container that randomly shuffles the pieces as they
exit back onto the same conveyor in random orientations before being fed
into the next cutting/shredding operation.

[0055] While the invention has been described in conjunction with specific
embodiments, it is evident that many alternatives, modifications,
permutations and variations will become apparent to those skilled in the
art in light of the foregoing description. Accordingly, it is intended
that the present invention embraces all such alternatives, modifications
and variations as fall within the scope of the claims below.

Patent applications by Davor Juravic, San Pedro, CA US

Patent applications by Dwayne P. Mcdowell, Ii, San Pedro, CA US

Patent applications by Geoffrey Chase Thornhill, San Francisco, CA US

Patent applications by Oscar Ortiz, Hawthorne, CA US

Patent applications by Yomayra Alvarez, Long Beach, CA US

Patent applications in class INHIBITING CHEMICAL OR PHYSICAL CHANGE OF FOOD BY CONTACT WITH A CHANGE INHIBITING CHEMICAL AGENT OTHER THAN AN ANTIOXYGEN AGENT

Patent applications in all subclasses INHIBITING CHEMICAL OR PHYSICAL CHANGE OF FOOD BY CONTACT WITH A CHANGE INHIBITING CHEMICAL AGENT OTHER THAN AN ANTIOXYGEN AGENT